Dispersion paint

ABSTRACT

Presented and described is a dispersion paint containing, in each case based on the total weight of the dispersion paint, a) 1% to 15% by weight of pigment, b) 30% to 60% by weight of filler, c) 1% to 25% by weight of polymer, d) 0.1% to 3.5% by weight of alkali metal alkyl siliconate, e) 25% to 70% by weight of water, wherein the pH of the dispersion paint is from 10 to 12. Also described is a process for producing the dispersion paint. The dispersion paint is suitable for use in interior and/or exterior applications.

The present invention relates to a dispersion paint, to a process forproducing the dispersion paint, to the use of the dispersion paint andto the use of alkali metal alkyl siliconates for stabilizing dispersionpaints.

Various coating materials are known for the coating of substrates. Theseinclude not only silicate paints but also inter alia dispersion silicatepaints and polymer dispersion paints.

Silicate paints are two-component paints containing no organicconstituents. The two primary components of silicate paints are waterglass and a water glass-resistant pigment. Silicate paints are typicallyblended immediately before application by combining the two primarycomponents. Silicate paints therefore require several production stepsand the working thereof is generally difficult and requires a great dealof experience.

Dispersion silicate paints according to DIN 18363 contain not only thewater glass and the water glass-resistant pigment but also up to 5% byweight of organic constituents based on the total amount of dispersionsilicate paint. Organic constituents used are especially synthetic resindispersions. Further substances such as hydrophobizing agents may alsobe present in addition. The use of synthetic resin dispersions makes itpossible to provide dispersion silicate paints as one-component systems.

Both silicate paints and dispersion silicate paints typically have avery strongly alkaline pH of up to 13 which necessitates relativelyonerous precautions in terms of occupational health and safety.

Polymer dispersion paints, also known as dispersion paints, typicallycontain relatively large amounts of organic-chemical constituents, inparticular of synthetic resins such as polymers, in particular in theform of synthetic resin dispersions. In order to ensure sufficientstorage stability, dispersion paints typically require preservativessuch as isothiazoline for example. However these can bring about skinirritation and other irritation in allergy sufferers in particular.

EP 1 297 079 B1 describes a dispersion paint containing polymerdispersion, pigment and/or filler, water glass and water. Thisdispersion paint has the feature that it requires no preservatives.However, due to the presence of water glass an inorganic binder isadditionally present, as a result of which the properties of thedispersion paint, in particular its workability, may be impaired.

DE 1 031 910 describes an alkyd resin emulsion paint containing titaniumdioxide, fillers, an alkyd resin and water. Immediately before use thispaint is admixed with sodium methyl siliconate, as a result of which themodified paint exhibits better cleanup properties than alkyd resinemulsion paints without sodium methyl siliconate. DE 1 031 910 gives noindication about the pH of the alkyd resin emulsion paint, its storagestability or about the presence of preservatives. In addition, an alkydresin emulsion paint containing sodium methyl siliconate is not intendedfor storage according to DE 1 031 910.

Proceeding from the prior art elucidated hereinabove it is an object ofthe invention to provide a dispersion paint which is substantially freefrom preservatives, has a good storage stability and/or is readilyworkable.

All or some of these objects are achieved according to the invention bythe dispersion paint of claim 1, the process according to claim 11, theuse according to claim 13 and the use according to claim 14.

Advantageous embodiments of the invention are specified in the dependentclaims and are elucidated in detail hereinbelow.

The dispersion paint according to the invention has a pH of 10 to 12 andcontains, in each case based on the total weight of the dispersionpaint, the following constituents:

-   -   a. 1% to 15% by weight of pigment,    -   b. 30% to 60% by weight of filler,    -   c. 1% to 25% by weight of polymer,    -   d. 0.1% to 3.5% by weight of alkali metal alkyl siliconate,    -   e. 25% to 70% by weight of water.

It has now been found that, surprisingly, combining 1% to 15% by weightof pigment with 30% to 60% by weight of filler, 1% to 25% by weight ofpolymer, 0.1% to 3.5% by weight of alkali metal alkyl siliconate and 25%to 70% by weight of water in a dispersion paint having a pH of 10 to 12affords a dispersion paint in which the components exhibit exceptionalcompatibility with one another. As a result, surfaces coated with thedispersion paint according to the invention have a more homogeneousappearance. This is apparent in particular in that the surfaces coatedwith the dispersion paint according to the invention are formed veryuniformly through good levelling. As a result the dispersion paintaccording to the invention has exceptional workability. It has furtherbeen found that the dispersion paint according to the invention shows nodiscolorations after a storage time of several weeks even withoutpreservatives. It has finally been found that the pH of the dispersionpaint according to the invention remained substantially constant over astorage time of several weeks.

Without being bound to a particular theory the alkali metal alkylsiliconate appears to stabilize the dispersion paint, in particular thepH of the dispersion paint, and also to ensure good compatibility of thecomponents. Herein, the alkali metal alkyl siliconate appears to act asa pH buffer. The presence of exclusively organic binders appears topromote a good compatibility between the components at the pH of thedispersion paint. This activity was not foreseeable in light of therequired additions mentioned in DE 1 031 910 for alkali metal alkylsiliconate solutions with concentrations of up to 40% of the additionsfor increasing the storage stability of the alkali metal alkylsiliconate solutions.

Dispersion paints contemplated in the context of the invention are inparticular interior dispersion paints, exterior dispersion paints,silicone resin paints and dispersion-based renders, including interiorand exterior renders.

Alkali metal alkyl siliconates according to the invention are inparticular compounds having the formula MOSi(R)(OH)₂, wherein M is analkali metal and R is an alkyl substituent. Alkali metal alkylsiliconates may be obtained for example by reaction of alkyl silanetriol with an alkali metal hydroxide. The production of alkali metalalkyl siliconate solutions, in particular aqueous solutions, isdescribed for example in DE 1 031 910.

In the compounds MOSi(R)(OH)₂ suitable for the alkali metal alkylsiliconate according to the invention, the alkali metal M may inparticular be selected from the group consisting of lithium, sodium,potassium and mixtures thereof. The alkyl substituent R is preferablyselected from the group consisting of methyl, ethyl, n-propyl,iso-propyl, n-butyl, iso-butyl, tert-butyl, n-pentyl, iso-pentyl,tert-pentyl, neopentyl, phenyl, aryl, and cyclohexyl. It is preferablewhen the alkyl substituent is methyl. It is more preferable when thealkali metal alkyl siliconate of the dispersion paint according to theinvention is selected from the group consisting of lithium methylsiliconate, sodium methyl siliconate and potassium methyl siliconate. Itis most preferable when the alkali metal alkyl siliconate is potassiummethyl siliconate. These alkali metal alkyl siliconates, in particularpotassium methyl siliconate, result in homogeneous surfaces and arereadily manageable.

In the dispersion paint according to the invention the alkali metalalkyl siliconate is contained in an amount of 0.1% to 3.5% by weightbased on the total weight of the dispersion paint. It is preferable whenthe dispersion paint according to the invention contains 0.1% to 2% byweight, in particular 0.3% to 2% by weight or 0.5% to 1.5% by weight, ofalkali metal alkyl siliconate in each case based on the total weight ofthe dispersion paint. Dispersion paints having these contents show agood workability and a good storage stability.

According to the invention the dispersion paint contains 1% to 15% byweight of pigment. Various substances are suitable as the pigment. It ispreferable when the pigment is selected from the group consisting oftitanium dioxide, iron oxide yellow, arylide (monoazo), bismuthvanadate, perinone, rutile-tin-zinc, quinacridone, diketopyrrolopyrrole,iron oxide red, phthalocyanine blue, dioxazine, cobalt blue, ultramarineblue, phthalocyanine green, chromium oxide green, cobalt green, colorcarbon black, iron oxide black, pyrazoloquinazolone, naphthol ASmonoazopigment and mixtures thereof. In a preferred embodiment of theinvention the dispersion paint contains 3% to 13% by weight of pigment,more preferably 5% to 12% by weight of pigment.

In one embodiment it is preferable to employ inorganic pigments.Examples of inorganic pigments are oxides such as titanium dioxide, ironoxides, for example P.Y. 42, P.R. 101, P.Bk. 11, chromium oxide green,for example P.G. 17, mixed phase pigments, for example cobalt oxide blueP.B. 28 and green P.G. 50, bismuth vanadate P.Y. 184, rutile-tin-zincP.O. 216, silicates, for example ultramarine blue P.B. 29 and carbon,for example carbon black P.Bk. 7.

In a further embodiment it is preferable to employ organic pigments.Examples of organic pigments are azo pigments, for example arylideyellow (monoazo) P.Y. 74, polycyclic pigments, for example quinacridoneP.R. 122, perinone P.O. 43, pyrazoloquinazolone P.O. 67,diketopyrrolopyrrole (DPP) P.R. 254, dioxazine P.V. 23 and metal complexpigments, for example copper phthalocyanine blue P.B. 15:3 and greenP.G. 7.

The designations used for the examples of inorganic and organic pigmentscorrespond to the generic names of the color index of the BritishSociety of Dyers and Colourists.

In a further embodiment mixtures of inorganic pigments and organicpigments are employed.

Use of the recited pigments makes it possible to produce coloreddispersion paints covering substantially the entire color spectrum.

In addition to the components pigment, polymer, alkali metal alkylsiliconate and water, the dispersion paint according to the inventioncontains filler. The filler is preferably selected from the groupconsisting of dolomite, barium sulfate, feldspar, quartz, calciumcarbonate, mica, kaolin, calcinated kaolin, talc, diatomaceous earth andmixtures thereof. The filler is more preferably a mixture of at leastcalcium carbonate and kaolin. Such fillers afford dispersion paintshaving a good workability.

Calcium carbonate may be employed in different forms, for example in theform of chalk or calcite.

Practical tests have shown that dispersion paints affording particularlyhomogeneous coatings are obtained when the filler particles are small.It is advantageous when the filler particles of the dispersion paintaccording to the invention have a size of less than 100 μm, inparticular less than 80 μm, preferably of 0.1 to 50 μm, more preferablyof 1 to 30 μm. Processes for determining the particle size are known tothose skilled in the art. For example the particle size may bedetermined by means of a grindometer according to DIN EN ISO 1524, inparticular according to DIN EN ISO 1524:2013-06. The particle size ofthe fillers relates in particular to the maximum agglomerate size in thedispersion paint. Furthermore, the particle size, in particular theparticle size distribution, may also be determined by means oftransmission electron microscopy.

According to the invention the pH of the dispersion paint is from 10 to12, preferably from 10.5 to 11.5. It was found that dispersion paintshaving the recited pH values exhibit little discoloration, if any, evenupon storage over several weeks, even when substantially free frompreservatives. It is yet more preferable when the pH of the dispersionpaint is from 10.5 to 11.4. Dispersion paints according to the inventionhaving such pH values had the additional advantage of being usable evenwithout particular occupational health and safety precautions.

The pH may be adjusted for example by addition of alkaline substances,also known as alkalizers. Examples of alkaline substances are alkalimetal hydroxides such as lithium, sodium and/or potassium hydroxide,alkaline earth metal hydroxides such as magnesium, calcium and/or bariumhydroxide, ammonium hydroxide, xonotlite (6CaO·6SiO₂·H₂O) and/orittringite (Ca₆[Al(OH)₆]₂(SO₄×26 H₂O)). The xonotlite preferably has amonoclinic crystal system (monoclinic xonotlite). It has been found thatxonotlite and/or ittringite are particularly advantageously employablein combination with the alkali metal alkyl siliconate present in thedispersion paint according to the invention. In particular, dispersionpaints containing xonotlite and/or ittringite as alkalizers in additionto alkali metal alkyl siliconate exhibit an increased pH stability. In apreferred embodiment of the invention the dispersion paint according tothe invention contains in addition to alkali metal alkyl siliconatealkalizers in an amount from 0.005% to 3% by weight, in particular from0.01% to 1% by weight, based on the total composition of the dispersionpaint. In particular the dispersion paint according to the invention maycontain 0.005% to 3% by weight, in particular 0.01% to 1% by weight, ofxonotlite and/or ittringite based on the total composition of thedispersion paint.

In one embodiment of the invention the pH of the dispersion paintaccording to the invention remains substantially constant over a periodof at least 4 weeks, preferably at least 8 weeks, more preferably atleast 12 weeks, yet more preferably at least 16 weeks, yet morepreferably at least 20 weeks.

According to the invention the dispersion paint contains 1% to 25% byweight of polymer based on the total weight of the dispersion paint. Itis preferable when the dispersion paint contains 2% to 23% by weight,more preferably 4% to 20% by weight, of polymer, in each case based onthe total weight of the dispersion paint. The reported contents ofpolymer in the dispersion paint relate in each case to the polymer assolids content. However, it is preferable when the polymer is added inthe form of a dispersion, in particular an aqueous dispersion, duringthe production of a dispersion paint. It is advantageous when thesepolymer dispersions, in particular the aqueous polymer dispersions,contain 40% to 70% by weight, preferably 45% to 60% by weight, morepreferably 45% to 55% by weight, of polymer. If the polymer is added asan aqueous polymer dispersion the water of the polymer dispersion istreated as part of the total water content of the dispersion paint.Dispersion paints containing polymer in these amounts have shown goodworking properties.

Various polymers are suitable as the polymer of the dispersion paint. Itis preferable when the polymer of the dispersion paint according to theinvention contains at least one polymer and/or copolymer based on atleast one monomer selected from the group consisting of acrylic acid,acrylic acid derivatives, acrylic acid esters, methacrylic acid,methacrylic acid derivatives, methacrylic acid esters, styrene, styrenederivatives, N-vinylpyrrolidone, acrylonitrile, vinyl acetate, vinylpropionate, ethylenically unsaturated carboxylic acids, ethylenicallyunsaturated carboxylic acid esters, ethylenically unsaturated carboxylicacid anhydrides, ethylenically unsaturated carboxylic acid amides andcarboxylic acid vinyl esters. It is particularly preferable when thepolymer of the dispersion paint contains at least one polymer based onacrylic acid derivatives and/or styrene. When using acrylic acid estersand/or methacrylic acid esters it is preferable for the alcoholsubstituent to contain 1 to 12 carbon atoms. The alcohol substituent mayfurther be branched or unbranched. In a preferred embodiment the polymerof the dispersion paint consists of at least one of the abovementionedpolymers and/or copolymers.

The dispersion paint according to the invention may additionally containas further additives dispersants, wetting agents, thickeners,stabilizers, defoamers and/or hydrophobizing agents.

Examples of thickeners are alcohol alkoxylates, ethylene oxide-propyleneoxide copolymers, maleic anhydride-diisobutylene copolymers, polyacrylicand polymethacrylic acid and salts thereof, methylcelluloses, carboxymethylcelluloses, hydroxyl methylcelluloses, polyurethanes, alkali metalphosphates and salts of modified phosphoric acids, and mixtures thereof.

Examples of defoamers are polyglycols, triglycerides,polysiloxane-polyether copolymers and silicone oils.

Examples of hydrophobizing agents are in particular oligomeric andpolymeric siloxanes and silicone resins.

In a preferred embodiment the dispersion paint according to theinvention is substantially free from preservatives, in particular fromisothiazolines.

The invention further provides a process for producing the dispersionpaint according to the invention, comprising the steps of

-   -   a. providing a composition containing, in each case based on the        total weight of the dispersion paint,        -   i. 1% to 15% by weight of pigment,        -   ii. 30% to 60% by weight of filler,        -   iii. 1% to 25% by weight of polymer,        -   iv. 0.1% to 3.5% by weight of alkali metal alkyl siliconate,        -   v. 25% to 70% by weight of water,    -   b. dispersing the components recited in a.,    -   c. adjusting the pH to a value of 10 to 12.

The recited steps may be performed in any desired sequence, preferablythe recited steps are performed in the recited sequence.

What is stated with regard to the alkali metal alkyl siliconate inconnection with the dispersion paint according to the invention alsoapplies equally to the alkali metal alkyl siliconate of the processaccording to the invention.

What is stated with regard to the pigment in connection with thedispersion paint according to the invention also applies equally to thepigment of the process according to the invention.

What is stated with regard to the filler in connection with thedispersion paint according to the invention also applies equally to thefiller of the process according to the invention.

What is stated with regard to the pH and to the alkaline substance inconnection with the dispersion paint according to the invention alsoapplies equally to the pH and to the alkaline substance of the processaccording to the invention.

What is stated with regard to the polymer in connection with thedispersion paint according to the invention also applies equally to thepolymer of the process according to the invention.

The dispersion paint according to the invention is suitable for varioususes. It is in particular suitable for the use in interior and/orexterior applications.

The invention likewise relates to the use of alkali metal alkylsiliconates, in particular of potassium methyl siliconate, forstabilizing dispersion paints.

The invention is hereinbelow more particularly elucidated using exampleswhich are, however, only explanatory and nonlimiting.

EXAMPLES

Dispersion paints having the following formulations reported in table 1were produced by mixing the constituents stated in table 1, amountsadded being in % by weight in each case.

TABLE 1 Constituent Formulation A Formulation B Titanium dioxide 6 11Styrene acrylate (50% by 19 11 weight in water) Potassium methylsiliconate 1 1.5 Calcium carbonate 21.7 32.5 Kaolin 20.8 8 Alkalinecompound 0.05 0.5 Defoamer 0.2 0.28 Thickener 0.5 0.75 Wetting agent0.46 0.3 Water 30.29 34.17 pH 11.3 11.4

The formulations A and B showed a storage stability of more than 6months without discolorations and were readily workable. In particularthe formulations showed a good workability and after applicationafforded surfaces having a homogeneous overall impression. After 6months, formulation A had a pH of 11.3 and formulation B had a pH of11.4.

1. A dispersion paint comprising: (a) 1% to 15% by weight of pigment;(b) 30% to 60% by weight of filler; (c) 1% to 25% by weight of polymer;(d) 0.1% to 3.5% by weight of alkali metal alkyl siliconate; (e) 25% to70% by weight of water; and (f) 005% to 3% by weight xonotlite and/orettringite, wherein the pH of the dispersion paint is from 10 to 12 andthe % by weight is based on the total weight of the dispersion paint. 2.The dispersion paint of claim 1, wherein the dispersion paint contains0.1% to 2% by weight alkali metal alkyl siliconate.
 3. The dispersionpaint of claim 1, wherein the alkali metal alkyl siliconate is potassiummethyl siliconate.
 4. The dispersion paint of claim 1, wherein thepigment is selected from the group consisting of titanium dioxide, ironoxide yellow, arylide (monoazo), bismuth vanadate, perinone,rutile-tin-zinc, quinacridone, diketopyrrolopyrrole, iron oxide red,phthalocyanine blue, dioxazine, cobalt blue, ultramarine blue,phthalocyanine green, chromium oxide green, cobalt green, color carbonblack, iron oxide black, pyrazoloquinazolone, naphthol ASmonoazopigment, and mixtures thereof.
 5. The dispersion paint of claim1, wherein the filler is selected from the group consisting of dolomite,barium sulfate, feldspar, quartz, calcium carbonate, mica, kaolin,calcinated kaolin, talc, diatomaceous earth and mixtures thereof.
 6. Thedispersion paint of claim 5, wherein the filler is a mixture comprisingat least calcium carbonate and kaolin.
 7. The dispersion paint of claim1, wherein the pH of the dispersion paint is from 10.5 to 11.5.
 8. Thedispersion paint of claim 1, wherein the pH of the dispersion paintremains substantially constant over a period of at least 4 weeks.
 9. Thedispersion paint of claim 1, wherein the dispersion paint comprises 2%to 23% by weight of polymer based on the total weight of the dispersionpaint.
 10. The dispersion paint of claim 9, wherein the polymer containsat least one polymer and/or copolymer based on at least one monomerselected from the group consisting of acrylic acid, acrylic acidderivatives, acrylic acid esters, methacrylic acid, methacrylic acidderivatives, methacrylic acid esters, styrene, styrene derivatives,N-vinylpyrrolidone, acrylonitrile, vinyl acetate, vinyl propionate,ethylenically unsaturated carboxylic acids, ethylenically unsaturatedcarboxylic acid esters, ethylenically unsaturated carboxylic acidanhydrides, ethylenically unsaturated carboxylic acid amides andcarboxylic acid vinyl esters.
 11. The dispersion paint of claim 1,wherein the dispersion paint further comprises at least one additiveselected from the group consisting of dispersants, wetting agents,thickeners, stabilizers, defoamers and/or hydrophobizing agents.
 12. Aprocess for producing a dispersion paint comprising: (a) providing acomposition comprising: (i) 1% to 15% by weight of pigment; (ii) 30% to60% by weight of filler; (iii) 1% to 25% by weight of polymer; (iv) 0.1%to 3.5% by weight of alkali metal alkyl siliconate; and (v) 25% to 70%by weight of water; (b) dispersing the components recited in step a);and (c) adjusting the pH to a value of 10 to
 12. wherein the % by weightis based on the total weight of the dispersion paint.
 13. The process ofclaim 12, wherein: the composition comprises 0.1% to 2% by weight of thecomposition of alkali metal alkyl siliconate; the pigment is selectedfrom the group consisting of titanium dioxide, iron oxide yellow,arylide (monoazo), bismuth vanadate, perinone, rutile-tin-zinc,quinacridone, diketopyrrolopyrrole, iron oxide red, phthalocyanine blue,dioxazine, cobalt blue, ultramarine blue, phthalocyanine green, chromiumoxide green, cobalt green, color carbon black, iron oxide black,pyrazoloquinazolone and mixtures thereof; the pH of the dispersion paintis from 10.5 to 11.5, wherein the pH remains substantially constant overa period of at least 4 weeks; the composition comprises 2% to 23% byweight of the composition of polymer wherein the polymer comprises atleast one monomer selected from the group consisting of acrylic acid,acrylic acid derivatives, acrylic acid esters, methacrylic acid,methacrylic acid derivatives, methacrylic acid esters, styrene, styrenederivatives, N-vinylpyrrolidone, acrylonitrile, vinyl acetate, vinylpropionate, ethylenically unsaturated carboxylic acids, ethylenicallyunsaturated carboxylic acid esters, ethylenically unsaturated carboxylicacid anhydrides, ethylenically unsaturated carboxylic acid amides, andcarboxylic acid vinyl esters; and/or the composition further comprisesat least one additive selected from the group consisting of dispersants,wetting agents, thickeners, stabilizers, defoamers and/or hydrophobizingagents.
 14. A process for coating interior and/or exterior substratescomprising applying the dispersion paint of claim 1 to a substrate. 15.A method of stabilizing a dispersion paint comprising mixing 0.1% to3.5% by weight of an alkali metal siliconate with the dispersion paint,wherein the % by weight is based on the total weight of the dispersionpaint.
 16. The dispersion paint of claim 1, wherein the dispersion paintcontains 0.5% to 1.5% by weight alkali metal alkyl siliconate.
 17. Thedispersion paint of claim 1, wherein the pH of the dispersion paint isfrom 10.5 to 11.4.
 18. The dispersion paint of claim 1, wherein the pHof the dispersion paint remains substantially constant over a period ofat least 20 weeks.
 19. The dispersion paint of claim 1, wherein thedispersion paint comprises 4% to 20% by weight of polymer based on thetotal weight of the dispersion paint.